Method of electrolytically assisted carbochlorination

ABSTRACT

Method of combining industrial processes having inherent carbon capture and conversion capabilities offering maximum flexibility, efficiency, and economics while enabling environmentally and sustainably sound practices. Maximum chemical energy is retained throughout feedstock processing. A hybrid thermochemical cycle couples staged reforming with hydrogen production and chlorination. Hydrogen generated is used to upgrade feedstocks including bitumen, shale, coal, and biomass. Residues of upgrading are chlorinated, metals of interest are removed, and the remainder is reacted with ammonia solution and carbon dioxide to form carbonate minerals. The combination provides emissions free production of synthetic crude oil and derivatives, as well as various metals and fertilizers. Sand and carbonate minerals are potentially the only waste streams. Through this novel processing, major carbon dioxide reduction is afforded by minimizing direct oxidation. Supplemental heat to run the reactions is obtained through external means such as concentrated solar, geothermal, or nuclear.

RELATED U.S. APPLICATION DATA

This application is a divisional of U.S. application Ser. No.14/240,569, filed on Feb. 24, 2014, now U.S. Pat. No. 9,163,297, whichis a national stage entry of international (PCT) Patent Appl. No.PCT/US/053980, filed on Apr. 7, 2013, which claims priority to theprovisional U.S. application Ser. No. 61/680,393, filed on Aug. 7, 2012and U.S. application Ser. No. 61/786,477, filed on Mar. 15, 2013, theentire disclosure of each of which is incorporated by reference as ifset forth in their entirety herein.

TECHNICAL FIELD

The present invention relates generally to a system and method forimproved material utilization in industrial processing. Morespecifically, the present invention addresses existing challenges withcarbon and waste stream management of major processes of thepetrochemical and metallurgy industries. More specifically still, thepresent invention utilizes a reconfigurable set of processes hot-coupledto each other enabling high-efficiency carbon capture and conversion aswell as comprehensive waste stream management capabilities ideal for newplant design or retrofit.

BACKGROUND ART

Rising demand for fossil fuels, exasperated by rapidly developingnations, is driving the need for more efficient utilization of limitednatural resources in conjunction with the development of alternativeenergy sources. Many modern advances in long utilized petrochemicalpractices such as gasification and hydrotreatment are enabling the costeffective utilization of so called unconventional fuels. Hybrid designssuch as those discussed in papers “Development of Multifunctional EnergySystems” (Cai et al., Energy, 2010) and “Optimization Framework for theSimultaneous Process Synthesis, Heat and Power Integration of aThermochemical Hybrid Biomass, Coal, and Natural Gas Facility” (Balibanet al., Computers & Chemical Engineering, 2011) enable the conversion ofnon-conventional fuels such as coal and natural gas as well as biomassand waste to be converted to direct replacements or additives forpetrochemicals conventionally derived from oil. Furthermore, they arecapable of utilizing carbon dioxide as a carbon source for conversion tosynthetic fuels, oils, and other carbon materials.

these practices do have substantial costs involved however. Capitolcosts of equipment as well as further energy costs are incurreddepending on the chosen technology and level of carbon dioxidemanagement sought. The reliance on air separation techniques common inhigh efficiency and especially carbon sequestration applications is onesubstantial cost. Further notable costs of such systems are hydrogenproduction methods that typically rely on direct oxidation of fuelinputs which in turn puts a greater load on carbon capture systems. Analternative method of hydrogen production via electrolysis is emissionsfree but even with onsite electricity production (which typically is notemissions free or highly efficient) represents a steep energy penalty.Even state of the art staged reforming processes coupled to numerouscomplementary subsystems rely to a large extent on legacy practices ofenergy production through direct oxidation and may or may not manage theresulting carbon dioxide produced. (US 2012/0073198 A1, U.S. Pat. No.7,674,443) What is needed is a superstructure that takes advantage ofthe level of maturity of such legacy processes while integratingadvances in alternative energy sources to efficiently deliver processheat. The present invention accomplishes this through the novelintegration of hydrogen production with the indirect oxidation bycarbochlorination of pyrolysis residues. Through this arrangement, heatis conserved and directed at hydrogen production and carbon dioxideformation is kept to a minimum.

Martynov et al. has shown in “Water and Hydrogen in Heavy Liquid MetalCoolant Technology” (Progress in Nuclear Technology, 2005) that moltenlead-bismuth eutectic is an ideal catalyst for steam methane reactions.Combining this advantageous method of hydrogen production with heatamplification techniques allows for a range of viable alternative energyinputs such as direct or indirect heating provided by an advanced hightemperature modular nuclear reactor.

Through this unique arrangement of processes, a large number ofmetallurgical subsystems may be integrated with a variety of synergisticbenefits. Those of ordinary skill in the art should recognize theintegration of a flash smelter provides for both the management ofsmelter off gases and an inherent drossing mechanism within the moltenmetal steam methane reactor. Similarly, steel production throughrecycling and direct reduction can be incorporated with highlybeneficial off gas processing simultaneously complementing thecarbochlorination process. A variety of processing methods are availablefor the extraction of valuable base metals from the feedstock throughgaseous and electrochemical methods. In addition to the precious metalsinherently captured by the molten metal steam methane reforming, rareearth elements (as well as the various radioactive species typicallyassociated with them) are captured and concentrated by carbochlorinationtechniques that can be removed through methods already known in the art.(U.S. Pat. Nos. 5,039,336, 5,569,440) Also disclosed is a method ofoxidizing the carbon component of carbochlorination residue using metaloxides from integrated processes as well as a novel electrochemicalcationic exchange for extraction of residual components utilizing asolid electrolyte. (U.S. Pat. No. 4,664,849) Those of ordinary skill inthe art will undoubtedly recognize other varying benefits of the processintegration enabled by the present invention. Finally, by exploiting astaged reforming operation utilizing hydrogen produced in the steammethane reactor, oxidation of feedstock is minimized and hydrogenationis maximized. Feedstock impurities are internally managed and aplurality of options for their removal is available. One of the moreunique features enabled is the production of carbonate minerals througha modified Solvay process utilizing the metal chlorides produced viacarbochlorination. (EP 0013586131, US 2013/0039824 A1) This along withinternal reprocessing of carbon dioxide relieves or eliminates the needfor dedicated carbon capture subsystems and their attributed energylosses.

DISCLOSURE OF INVENTION

The present invention addresses the issue of carbon dioxide managementin a staged reforming operation through tightly integrating methods ofpetrochemical processing, metallurgy, and ammonia-soda processing. Heatis generated by methods external to the invention and used to raisefeedstock temperature to a predetermined level. Heat amplification aswell as emissions management is inherently embodied within the inventionby multiple direct contact heat exchanges between integrated processes.Thermal energy accumulated in the high-temperature subsystems isdissipated through endothermic steam methane reactions producing bulkhydrogen for consumption by coupled processes. Within these hightemperature subsystems, heat from the carbochlorination of pyrolysisresidues is generated and supplemented through the hot-coupling offurther integrated processes. Carbon dioxide generated incarbochlorination is stripped of metal chlorides and combined withproduced hydrogen to form a synthesis gas. This hot synthesis gas isemployed in the pyrolysis of the feedstock and the combined gases aresent to a hydrotreatment vessel for upgrading and removal of impuritiessuch as sulfur, halogens, nitrogen, and heavy metals. Gaseous impuritiessuch as hydrogen chloride and hydrogen sulfide are removed from the gasstream following condensation of the higher molecular weighthydrocarbons and the remaining gases are further processed or recycledthrough the system. Base metals can be extracted as gaseous or liquidchlorides, separated and processed to oxides or another separable form,or removed through electro-deposition. Noble metals are removed withlead, copper, and related metals as dross from the steam methanereactor. Rare earth and radioactive elements present are concentrated bythe carbochlorination and removed through cationic exchange, leaching,electrochemical, or other means. The remaining metal chloridesconsisting substantially of alkali/alkaline chlorides as well as metaloxides consisting substantially of silica with varying amounts mixedoxide minerals transfer their useful heat to the input streams and thechlorides may be utilized in a modified Solvay process producingammonium chloride and carbonate minerals. Carbon dioxide not mineralizedis further processed through a reverse water gas shift reactor or otherdedicated processing equipment as part of the gas cleanup and processingor recycled through the system. Carbon management is thus handledthrough minimization of direct oxidation, mineralization, and synthesisgas reprocessing.

BRIEF DESCRIPTION OF DRAWINGS

Further features, advantages and characteristics of the presentinvention will become apparent to a person of ordinary skill in the artfrom the following detailed description of best modes of carrying outthe present invention, made with reference to the included drawing, inwhich the reference numbers used for selected subsystems are listed inorder of appearance rather than by importance or stepwise fashion, andin which:

FIG. 1 illustrates the process integration of a number of embodiments ofthe present invention. Subsystems in bold are considered to be integralto the operation. Solid lighter outlined subsystems are believed to beideal to the operation, however alternatives are known to exist andthere may be advantageous arrangements not accounted for in theillustration. Dashed subsystems are considered to be advantageousembodiments but their exclusion is not considered detrimental in anyway. Double arrowed lines represent gas streams and single arrowsrepresent solids or (usually high temperature) liquids.

BEST MODES FOR CARRYING OUT THE INVENTION

With reference to FIG. 1, multiple configurations of the presentinvention can be arranged through the inclusion, exclusion, ormodification of various subsystems. To those of ordinary skill in theart it should become apparent that only a subset of applicablesubsystems has been included in the drawing and this should in no waylimit the present invention to such subset. In accordance with a bestmode of carrying out the present invention the drawing illustrates theintegration of staged reforming with residue chlorination featuringinherent carbon oxide, heat, and waste management.

In accordance with best modes, all examples are implied to have attachedto them an advanced high temperature nuclear reactor as a zero emissionsheat source. Furthermore, all supplementary heating, cooling, andelectricity required by the combination of integrated processes in theexamples is assumed to be provided by said reactor and relatedapparatus. For the purpose of this disclosure, supplementary should bedefined as any energy requirements not met by thermochemical changeswithin the proposed set of integrated subsystems. Further, in theexamples it should be assumed that an outlet temperature of roughly 700degrees centigrade is provided by the Supplemental Heating (1.02) andthe heating costs of said arrangement are on par with coal. All of theCore components: Steam Methane Reaction (1.05), Thermal Decomposition(1.06), Hot Solids Recycle (1.07), Electrochemical Processing (1.08),and Chlorination (1.09) plus all of the Recommended components:Supplemental Heating (1.02), Feed Preparation (1.03), Gas Cleanup andProcessing (1.10), Condensation/ Distillation (1.13), and Hydrotreatment(1.15) are assumed to be included in the examples.

For the purpose of further reference within the examples a briefexplanation of the subsystems shown in FIG. 1 is as follows:

-   1.01 Hydrogen Separation is to include any number of known    technologies for the production or separation of purified hydrogen    for use or sale. The bulk hydrogen production will be assumed to    proceed via the Steam Methane Reaction (1.05) subsystem and the    current subsystem is to supplement the bulk hydrogen production    through methods including purification by molecular sieves, pressure    swing absorption, proton conducting ceramics, but is also meant to    include production techniques such as electrolysis.-   1.02 Supplemental Heating is to include heat generated or used    outside of and supplemental to other integrated subsystems. This may    include a conventional boiler, gas or combined cycle turbine, or    fuel cell; in which case it converts produced gas into electricity    for sale or use. This subsystem is also meant to include any means    of external energy input such as direct or indirect heating or heat    recovery as well as electricity from solar, wind, or hydro for    example. In most cases it is assumed that this supplemental energy    is input substantially through steam to the Steam Methane Reaction    (1.05) or through electricity for the Electrochemical Processing    (1.08). Combined cycle configurations such as waste heat capture    through desalination would also be included in this subsystem.-   1.03 Feed Preparation is to include any crushing, grinding,    blending, pulping, pelletizing, de-watering, pre-heating or related    pre-processing applied to the feedstock which may be located on    premise or at a remote facility. The overall pre-processing required    is assumed to be largely dependent on locally available resources    and in turn impact the applicability of the integration of various    subsystems within a given locale. Essentially any materials may be    prepared and decomposed by the overall processing with the only    limitations to feedstock being whether it economically meets the    design requirements through local availability constraints.-   1.04 Flash Smelting is to include the necessary apparatus for the    smelting of sulfide ores or more precisely ore concentrates. This is    to include both primary and secondary smelting. In conjunction with    conventional flash smelting this is to include means of oxidizing    molten lead from the Steam Methane Reaction (1.05) and its    utilization within this subsystem or other applicable subsystems.    Preferably this means of oxidation provides a heated stream of    nitrogen enriched air to be utilized in other subsystems. All    outputs from this subsystem are preferably sent advantageously to    other subsystems; lead bullion to the Steam Methane Reaction (1.05),    slag to Chlorination (1.09), and sulfur dioxide to a Claus plant in    Gas Cleanup and Processing (1.10) for example. A further noteworthy    use of this subsystem may be expanded to calcination without    exceeding its disclosed scope.-   1.05 Steam Methane Reaction is to include any configuration of a    reactor or reactors operating by reacting steam with molten lead or    lead alloy at moderate to high temperature. Further included are    means or methods of removing oxygen from the molten lead or lead    alloy such as reaction with methane or other gases, use of a solid    oxide conducting ceramic, or direct carbon reduction for example.    Also included are the use of further oxidation agents such as carbon    dioxide or metal oxides and the overall management of oxygen levels.    Implied in this oxygen management is the accumulation or    concentration of metal oxide impurities along with noble metals    providing dross of significant economic potential.-   1.06 Thermal Decomposition is to include heating of the feedstock to    separate volatile materials as well as any process or apparatus used    for or in conjunction to this purpose. In accordance with best modes    of operation it is assumed that this subsystem is coupled to the    Steam Methane Reaction (1.05) and Chlorination (1.09) subsystems    which provide hot gases utilized by this subsystem to volatilize the    feedstock, in turn cooling and reacting the gases before processing    by Hydrotreatment (1.15). Feedstock may be fed directly to this    subsystem or as intermediate streams from other subsystems.    Regardless of the specific arrangement of this subsystem, it serves    to convert fed materials to gases and char residue consisting of    inert mineral, spent catalyst, and fixed carbon which are then    processed by Chlorination (1.09). This is in contrast to    conventional staged reforming involving direct oxidation and/or heat    reclamation.-   1.07 Hot Solids Recycle is to include processes reclaiming heat from    the remaining solid oxides exiting Chlorination (1.09). In    accordance with best modes it is assumed that this useful heat is to    be transferred to water/steam and that recovery of salts from brine    is to be included as well. These salts are then utilized in Gas    Cleanup and Processing (1.10) through the formation of carbonate    minerals. Oxides having their useful heat recycled may be discharged    as tailings or used within construction or other industries.-   1.08 Electrochemical Processing is to include a wide range of    processing methods available to advantageously drive redox reactions    through electrochemical means. This includes molten salt or gaseous    electrolysis through solid or liquid electrolytes/electrodes as well    as plasma processing. This subsystem is assumed to be operating    between or in tandem with the Steam Methane Reaction (1.05) and    Chlorination (1.09) subsystems and further includes the circulation    of molten lead between the two. In accordance with best modes it is    envisioned such lead circulation may be carried out by    magneto-hydro-dynamic pumping, conventional pumping, or gravity and    displacement. Within this subsystem, substantially all metals that    are not to be discharged to Hot Solids Recycle (1.07) are extracted    from the Chlorination (1.09) output. There may be methods employed    for this purpose that are equivalent, better than, or supplementary    to electrochemical processes that for the purposes of this    disclosure fall within this subsystem. Although conventionally    direct current is utilized in similar apparatus, the present    invention is not preferential to alternating or direct current    within this subsystem.

Slag removed from the primary reaction vessel would consist mainly ofsilicon, calcium, aluminum, and iron oxides as well as various tracemetals. The extraction of these elements in a reduced and/or purifiedform would be advantageous as a value-added product over the traditionaloption of using it as industrial filler, as energy has already beenadded to heat it to such a high temperature. Carbo-chlorination andoxide electrolysis are two methods among a range of possiblemetallurgical configurations that are presently adopted for suchrecovery. The present invention proposes a hybrid method ofplumbo-electro-chlorination. In said process, lead bullion ischlorinated and mixed with the slag within an alkali-halogen melt whichdissolves the oxides. The chloride would then react with highlyelectro-active oxides (alkali and alkaline earths) undergoingspontaneous metathesis reactions. Reactivity is further enhanced throughelectrolysis within the same cell consisting of active/regenerativeelectrodes composed of molten lead compounds. Lead bullion/lead chloridewould act as a cathode, the alkali-halogen melt with dissolved oxideswould be the electrolyte and lead/lead oxide would be used as the anodematerial completing the molten electrolysis cell. Lead is cycled fromthe main reaction vessel, drossed, chlorinated then oxidized and finallyreturned to the main reactor as an oxygen carrier to heat the mainvessel. Within this electrolysis setup, there exists the potential toselectivity and cost effectively remove nearly any of the remainingmetals through cathodic deposition, vapor transport, and hydro-leachingfrom the salt.

-   1.09 Chlorination is to include any method or apparatus utilized for    the purpose of indirect oxidation of the carbon constituent of the    char produced by Thermal Decomposition (1.06) subsystems and    chlorination of intermixed metals. This is in contrast to oxidation    methods typical of staged reforming or gasification in that metal    chlorides are produced. In accordance with a best mode of carrying    out the present invention embodiments such as a rotating kiln,    fluidized bed, manifold fluidized bed, or partially fluidized bed    seem most suitable. A plurality of chlorides can be allowed to    volatilize from the chlorinator then separated from the carbon    oxides produced or alternatively kept within a chloride melt and    electrodeposited. The present invention is not preferential to    either processing technique. Volatilized chlorides not captured for    removal will migrate to the Thermal Decomposition (1.06) subsystem,    reacting with present oxides, and drop out or are filtered from the    gas stream. Hot carbon monoxide from the Electric Arc Processing    (1.12) or a similar process is also utilized as an oxygen sink.    Further, carbon dioxide or various metal oxides and chlorides may be    introduced to moderate reactivity and temperature. Dependent on the    embodiment, thermal management is a major consideration for optimal    operation as the heat generated drives the Thermal Decomposition    (1.06) and Steam Methane Reaction (1.05) subsystems through transfer    of materials. Electrochemical Processing (1.09) is one method    available to maintain high operating temperatures with various    complementary benefits.-   1.10 Gas Cleanup and Processing is to include primarily the    management of sulfur and carbon dioxide which may include    conventional management processes such as acid gas stripping,    chlorine knockout, dust collection, ammonia collection, cryogenic    separation, sulfuric acid or Claus processes. Depending on the    embodiment, sulfur dioxide from the Flash Smelting (1.04) and    hydrogen sulfide from the Condensation\Distillation (1.13) may be    reacted directly in a Claus process replacing or relieving the need    for air or oxygen feed. Capture of either gas with calcium carbonate    is also commonly practiced. In accordance with best modes this    subsystem further utilizes alkali and alkaline chlorides from the    Hot Solids Recycle (1.07) subsystem in a modified Solvay process for    the capture of carbon dioxide as carbonate minerals. Within this    disclosure the use of the term alkali chloride(s) or alkaline    chloride(s) are considered to be synonymous and include Group 1 and    Group 2 elements due to similar processing reactions. Due to this    distinction, various methods of chlor-alkali, lime, and fertilizer    production may directly relate to this subsystem, although    Fertilizer Production (1.17) has its own subsystem maximal    separation both in classification and physical proximity of these    subsystems is considered in the best mode of carrying out the    present invention. Cleanup is performed on the uncondensed gases    from the Condensation/Distillation (1.12) subsystem and involves    removing hydrogen chloride, hydrogen sulfide, and ammonia produced    in the Hydrotreatment (1.15) from the gas. Carbon dioxide that is    not mineralized may be recycled by conventional synthesis gas    processing techniques operating within this subsystem or reprocessed    within the superstructure of the invention by passing it through.    Furthermore this subsystem may be expanded to include the entire    range of applicable petrochemical processes in which case the    synthesis gas processing involved has significant complementary    overlap with Petrochemical Production (1.16) subsystems.-   1.11 Coal Coking is to include means of contacting preheated coal    from the High Temperature Coal Hopper (1.14) with hot gases from the    Electric Arc Processing (1.12) volatilizing and cracking entrained    hydrocarbons and producing a coke product. Volatilized gases are    then sent to the Thermal Decomposition (1.06) subsystem while coke    and/or reduced metals present may be introduced to the Electric Arc    Processing (1.12) or other applicable processes.-   1.12 Electric Arc Processing is to include any configuration of    electric arc furnace apparatus that may further benefit the    integrated processes through: recycling of steels, production of    steel from direct reduced or electro won iron, acting as a high    temperature carbon monoxide source, an appropriate carbon sink for    coke, a high temperature apparatus for heating and reacting metals,    slags, or gases from other processes, formation of slag appropriate    as a heat carrier to other processes , reduction of silica or    alumina to their metallic forms, production of metal chlorides for    the chlorinator, or for leaching noble metals from molten metal to a    lead alloy suitable for introduction to the Steam Methane Reaction    (1.05). In accordance with best modes, a major advantage to    incorporating this subsystem would be utilizing electricity produced    through Supplemental Heating (1.02) to provide high temperature    gases to the Chlorination (1.09) and Coal Coking (1.11) subsystems.-   1.13 Condensation/Distillation is to include means for separating a    fraction or fractions of the gas stream from the Hydrotreatment    (1.15) producing a crude oil or varying fractions thereof for the    Petrochemical Production (1.16) subsystem. Uncondensed gases flow    through to Gas Cleanup and Processing (1.10).-   1.14 High Temperature Coal Hopper is to include means for preheating    coal to be sent to the Coal Coking (1.11) subsystem by contact with    hot gases from Hydrotreatment (1.15). Further, this direct contact    may be used to partially volatilize the coal producing a near-coke.    Methods of condensing a portion of the high molecular weight    fraction of the gas stream and passing it to the Coal Coking (1.11)    for cracking may also be utilized. Utilizing sulfur sorbent mixed    with the coal as well as circulation or fluidization between this    subsystem and the Hydrotreatment (1.15) and Coal Coking (1.11)    subsystems are considered best practices. Management of vaporous    mercury present in the gas feed could also be carried out in this    manner.-   1.15 Hydrotreatment is to include the processing of volatilized    gases from the Thermal Decomposition (1.06) with large amounts of    hydrogen generated by the Steam Methane Reaction (1.05) through a    high pressure moderate temperature reactor. It may further include    the utilization of conventional catalysts as well as alkali\alkaline    catalysts which react to form carbonates and drive the water gas    shift reaction. The overall object of the subsystem is to saturate    the hydrocarbon gases, simultaneously reacting to form hydrogen    sulfide, hydrogen chloride, and ammonia which can then be removed in    the Gas Cleanup and Processing (1.10) subsystem. Destruction of a    plurality of organic pollutants is further achieved within this    subsystem.-   1.16 Petrochemical Production is to include the processing and    handling of bulk or fractionated hydrocarbons from the    Condensation/Distillation (1.13) as well as light gases from Gas    Cleanup and Processing (1.10) and is meant to cover the entire range    of petrochemical processing. Also included are blending, refining,    and preparation for transport such as by pipeline or rail.-   1.17 Fertilizer Production is to include the integration of ammonia    production through reaction of hydrogen supplied by Hydrogen    Separation (1.01) and nitrogen supplied by other subsystems such as    the Flash Smelting (1.04) after passing through Gas Cleanup and    Processing (1.10). Further it is to include the production of    ammonium or alkali/alkaline salts such as carbonates, phosphates,    nitrates, sulfates, sulfides, or urea.

In one embodiment of the present invention, tar sand production may beof primary importance. Utilizing the Core and Recommended subsystems ofFIG. 1, along with Petrochemical Processing (1.16) a light sweetsynthetic crude oil for pipeline transportation is produced with zeroharmful emissions, wastewater, or hazardous tailings and complete carbonconversion conserves more chemical energy of the feedstock thanconventional processing. Sand and carbonates may be utilized along withsteam produced for further in-situ tar sand recovery. Furthermore,biomass and poly-metallic shale can be fed into the system takingadvantage of both the carbon conversion efficiency and metal separation.

Another embodiment of the present invention is beneficial where mixedsulfide ores may be within an economically reasonable distance ofmineable shale and coal formations. Utilizing the Core and Recommendedsubsystems of FIG. 1, along with the Flash Smelting (1.04), Coal Coking(1.11), Electric Arc Processing (1.12), and High Temperature Coal Hopper(1.14) a plurality of metals can be extracted with a lower environmentalfootprint than conventional operations.

In a further embodiment of the present invention, municipal watertreatment and solid waste management are integrated with districtheating and electricity generation. Utilizing the Core and Recommendedsubsystems of FIG. 1, Fertilizer Production (1.17) could be furtherintegrated to ensure valuable nutrients are recycled. Fischer-Tropschprocessing within the Gas Cleanup and Processing (1.10) subsystem canfurther be used to provide automotive fuels.

In a final embodiment of the present invention, all of the Core,Recommended, and Optional subsystems of FIG. 1 are utilized in a largescale combined cycle poly-generation plant providing electricity,heating, cooling, and fresh water to a large metropolitan area.Capitalizing on economies of scale, such a superstructure could operateon advantageous feed-in tariffs for the disposal of a variety of wastesover a wide geographical area. It would further be capable ofintegrating distributed generation into its regional power grid througha plurality of operational modes, operating high energy demandsubsystems during off-peak hours while lowering chemical output andinstead utilizing that chemical energy during periods of high demand.

INDUSTRIAL APPLICABILITY

The present invention finds industrial applicability in the clean energyindustry. In particular, the present invention relates to industrialapplicability in the petrochemical and metallurgy industries. Moreparticularly, the present invention finds industrial applicability inthe pollution management and environmental footprint context of a widerange of industrial processing methods.

SCOPE OF THE INVENTION

Having illustrated and described the principles of the system and methodof the present invention in various embodiments, it should be apparentto those skilled in the art that the embodiment can be modified inarrangement and detail without departing from such principles. Forexample, the carbonaceous feedstock may be entirely consumed on site ifpreferred. Therefore, the illustrated embodiments should be consideredonly as example of the invention and not as a limitation on its scope.Although the description above contains much specificity, these shouldnot be construed as limiting the scope of the invention but as merelyproviding illustrations of some of the presently preferred embodimentsof this invention. Further, it is appreciated that the scope of thepresent invention encompasses other embodiments which may become obviousto those skilled in the art, and that the scope of the present inventionis accordingly to be limited by nothing other than the appended claims,in which reference to an element in the singular is not intended to meanone and only one unless explicitly so stated, but rather one or more”.All structural and functional equivalents to the elements of theabove-described preferred embodiment that are known to those of ordinaryskill in the art are expressly incorporated herein by reference and areintended to be encompassed by the present claims. Moreover, it is notnecessary for a device or method to address each and every problemsought to be solved by the present invention for it to be encompassed bythe present claims.

The invention claimed is:
 1. An electrolytic process comprising, in asingle cell: electrolytically assisting a molten salt carbochlorinationthrough simultaneously: reacting a multi-phase residue of molten orsemi-molten salts, metals and metal compounds with a carbon compound anda chlorinating agent, either of which may be a solid, liquid, gas orsome combination thereof to provide a reacted residue and remainingmulti-phase residue of molten or semi-molten salts, metals, and metalcompounds; and processing the remaining multi-phase residue and reactedresidue with an electrochemical process utilizing one or more electrodesformed by molten lead and/or lead compounds which fluxes the multi-phaseresidue as well as selectively extracting elements into the moltenelectrodes.
 2. The process of claim 1, wherein the multi-phase residuefunctions as a catalyst or heat carrier.
 3. The process of claim 1,wherein the multi-phase residue comprises a lead alloy and furthercomprising routing at least some portion of the lead alloy to anoxidizing vessel.
 4. The process of claim 1, wherein thecarbochlorination produces an inert mineral residue comprising silicaand further comprises transferring the sensible heat of the residue in ahot solids recycle process before being discharged.
 5. The process ofclaim 1, further comprising extracting one or more metals from themulti-phase residue by further downstream processing.
 6. The process ofclaim 1, wherein some portion of the multi-phase residue undergoeselectrolysis in which metal chlorides and dissolved oxides can beremoved individually or as a plurality of electrodeposited metals. 7.The process of claim 1, wherein the multi-phase residue concentrateschlorinated rare earth elements and radionuclides which are separatedfrom the multi-phase residue.
 8. The process of claim 1, wherein thecarbochlorination process is fluxed by a molten lead compound comprisingof lead(ii) chloride.
 9. The process of claim 1, wherein theelectrochemical process removes oxygen from the multi-phase residue. 10.The process of claim 1, wherein the electrochemical process is performedusing plasma processing.